Backdrop:
I have been plowing snow with a 2001 425 xpedition. After about an hour the shifting stops working and I have to let it sit. I thought it was freezing up but it seems that after I let it sit and it cools down it will start shifting again. It has done this 4 times. When I say it won’t ****, it feels I might be able to really stomp on the shifter but I didn’t want to try that.
So the second and 3rd time it happened it would start after it cooled. Now it does go into reverse and the indicator light does come on but it won’t turn over. The time prior to this it acted the same but with some messing with the gears it finally turned over and started.
What I think is happening is that he tranny is getting hot and starting to swell up preventing easy shifting. I checked the oil but I cannot find a place to check the tranny fluid or even a place to grease anything.
I think the reason it is not starting it because of a wiring issue or safety switch that makes it think it is still in gear even though it is not.


Side note: I had to replace one of the clutches in there tranny last summer because a neighbor took off with the safety brake on and burnt it up. After I replaced it, it worked fine.
Next, I replaced the stator because the motor would only start if I had it hooked up to jumper cables. After I replaced this it would start no problem.
I currently have a new full size battery with a full charge and it will not turn over.
The recoil is broke so I can’t test this unless I take off the cover and use an impact to turn it over.
Help…

 

Anyone, bueller.... bueller.... fry?

 

Try the clutch pressure adjuster behind the rubber plug.Loosen the lock nut,turn the adjuster until you feel a little pressure then back off 1/8 turn.See if that helps with the shifting.The gear position sensor is on the right side. Item #15.Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse If it doesn't help,then could be the shift cam or shift fork problem.Item#5.Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse No separate transmission oil,uses the engine oil for the gears. All 5 and 1/2 quarts of it. If you haven't changed oil in awhile,you might try that also.5w40 either Polaris oil,Rotella 5w40 or equivalent.No energy conserving car oil as they have friction modifiers that screw with the clutches. Anything beyond this you may need a manual. Only one I've found is for the 2002 model,but engine is the same. 2002 Polaris Xpedition 425 Service Manual PDF Download

 

Changed oil, reset the tension and jumped the solenoid. Started right up, shifted well and got the 6 inches of snow plowed. oh, they didn't have rotella 10W40 so I used rotella 0w40.

During the plowing the neutral and reverse indicator completely stopped working.
I placed an order for the switch this am so I hope this is the faulty piece keeping the starter button from working.
Thanks so much for all your help!!